Robotic Surgical Devices, Systems, and Related Methods

ABSTRACT

The embodiments disclosed herein relate to various medical device components, including components that can be incorporated into robotic and/or in vivo medical devices. Certain embodiments include various modular medical devices for in vivo medical procedures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority as a continuation application to U.S.application Ser. No. 13/833,605, filed on Mar. 15, 2013 and entitled“Robotic Surgical Devices, Systems, and Related Methods,” which claimsthe benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application61/680,809, filed Aug. 8, 2012, and entitled “Robotic Surgical Devices,Systems, and Methods,” both of which are hereby incorporated herein byreference in their entireties.

TECHNICAL FIELD

The embodiments disclosed herein relate to various medical devices andrelated components, including robotic and/or in vivo medical devices andrelated components. Certain embodiments include various robotic medicaldevices, including robotic devices that are disposed within a bodycavity and positioned using a support component disposed through anorifice or opening in the body cavity. Further embodiment relate tomethods of operating the above devices.

BACKGROUND

Invasive surgical procedures are essential for addressing variousmedical conditions. When possible, minimally invasive procedures such aslaparoscopy are preferred.

However, known minimally invasive technologies such as laparoscopy arelimited in scope and complexity due in part to 1) mobility restrictionsresulting from using rigid tools inserted through access ports, and 2)limited visual feedback. Known robotic systems such as the da Vinci®Surgical System (available from Intuitive Surgical, Inc., located inSunnyvale, Calif.) are also restricted by the access ports, as well ashaving the additional disadvantages of being very large, very expensive,unavailable in most hospitals, and having limited sensory and mobilitycapabilities.

There is a need in the art for improved surgical methods, systems, anddevices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing a robotic surgical system, including arobotic device positioned inside a body and axis of rotation, accordingto one embodiment.

FIG. 2A is a perspective view of a robotic medical device, according toone embodiment.

FIG. 2B is a perspective view of a robotic medical device, according toone embodiment.

FIG. 2C is a cut-away view of an arm of a robotic medical device,according to one embodiment.

FIG. 2D is a sideview of a robotic medical device, according to oneembodiment.

FIG. 3A is a perspective view of a body portion of a robotic device andrelated equipment, according to one embodiment.

FIG. 3B is a perspective view of another body portion of a roboticdevice and related equipment, according to one embodiment.

FIG. 4A is an endlong view of the body portion of a robotic device andrelated equipment, according to one embodiment.

FIG. 4B is a sideview of the body portion of a robotic device andrelated equipment, according to one embodiment.

FIG. 5A is a sideview of a body portion of a robotic device and relatedequipment, according to one embodiment.

FIG. 5B is a side cross-sectional view of a body portion of a roboticdevice and related equipment, according to one embodiment.

FIG. 5C is a perspective cross-sectional view of a body portion of arobotic device and related equipment, according to one embodiment.

FIG. 5D is a side cross-sectional view of a body portion of a roboticdevice and related equipment, according to one embodiment.

FIG. 6 is an endlong cross-sectional view of a body portion of a roboticdevice, according to one embodiment.

FIG. 7A is a cross-sectional sideview of the upper arm of a roboticdevice, according to one embodiment.

FIG. 7B is a cross-sectional sideview of the upper arm of a roboticdevice from an alternate view, according to one embodiment.

FIG. 7C is a perspective internal view of the upper arm of a roboticdevice, according to one embodiment.

FIG. 8A is a sideview of a forearm of a robotic device, according to oneembodiment.

FIG. 8B is a cross-sectional view of a forearm of a robotic device,according to one embodiment.

FIG. 8C is another cross-sectional view of a forearm of a roboticdevice, according to one embodiment.

FIG. 8D is yet another cross-sectional view of a forearm of a roboticdevice, according to one embodiment.

FIG. 9A is cross-sectional sideview of the forearm of a robotic device,according to another embodiment.

FIG. 9B is another cross-sectional sideview of the forearm of a roboticdevice, according to another embodiment.

FIG. 10 is a perspective internal view of a forearm of a robotic device,according to another exemplary embodiment.

FIG. 11A contains a perspective view of an exemplary embodiment of therotary slip ring assembly according to an exemplary embodiment.

FIG. 11B contains another perspective view of an exemplary embodiment ofthe rotary slip ring assembly the embodiment of FIG. 11A.

FIG. 11C is a cross sectional sideview of the rotary slip ring assemblythe embodiment of FIG. 11A.

FIG. 11D is another cross-sectional sideview of the embodiment of FIG.11A.

FIG. 11E is an endview of the embodiment of FIG. 11A.

FIG. 11F is another cross-sectional sideview of the embodiment of FIG.11A, with associated components in the forearm.

FIG. 12A is a cutaway sideview of an exemplary embodiment of thesurgical device forearm and tool assembly.

FIG. 12B is a side view of the tool assembly, according to an exemplaryembodiment.

FIG. 13A is a perspective cutaway view of an exemplary embodiment of thesurgical device forearm showing an embodiment of a linear encoder.

FIG. 13B is a cross-sectional sideview of the embodiment of a linearencoder according to FIG. 13A.

FIG. 13C is an end view of the embodiment of a linear encoder accordingto FIG. 13A and showing the cross section of FIG. 13B.

FIG. 13D is a sideview of the embodiment of a linear encoder accordingto FIG. 13A.

DETAILED DESCRIPTION

The various systems and devices disclosed herein relate to devices foruse in medical procedures and systems. More specifically, variousembodiments relate to various medical devices, including robotic devicesand related methods and systems.

It is understood that the various embodiments of robotic devices andrelated methods and systems disclosed herein can be incorporated into orused with any other known medical devices, systems, and methods. Forexample, the various embodiments disclosed herein may be incorporatedinto or used with any of the medical devices and systems disclosed incopending U.S. applications Ser. No. 11/766,683 (filed on Jun. 21, 2007and entitled “Magnetically Coupleable Robotic Devices and RelatedMethods”), U.S. Ser. No. 11/766,720 (filed on Jun. 21, 2007 and entitled“Magnetically Coupleable Surgical Robotic Devices and Related Methods”),U.S. Ser. No. 11/966,741 (filed on Dec. 28, 2007 and entitled “Methods,Systems, and Devices for Surgical Visualization and DeviceManipulation”), U.S. Ser. No. 61/030,588 (filed on Feb. 22, 2008), U.S.Ser. No. 12/171,413 (filed on Jul. 11, 2008 and entitled “Methods andSystems of Actuation in Robotic Devices”), U.S. Ser. No. 12/192,663(filed Aug. 15, 2008 and entitled Medical Inflation, Attachment, andDelivery Devices and Related Methods”), U.S. Ser. No. 12/192,779 (filedon Aug. 15, 2008 and entitled “Modular and Cooperative Medical Devicesand Related Systems and Methods”), U.S. Ser. No. 12/324,364 (filed Nov.26, 2008 and entitled “Multifunctional Operational Component for RoboticDevices”), U.S. Ser. No. 61/640,879 (filed on May 1, 2012), U.S. Ser.No. 13/493,725 (filed Jun. 11, 2012 and entitled “Methods, Systems, andDevices Relating to Surgical End Effectors”), U.S. Ser. No. 13/546,831(filed Jul. 11, 2012 and entitled “Robotic Surgical Devices, Systems,and Related Methods”), U.S. Ser. No. 61/680,809 (filed Aug. 8, 2012),U.S. Ser. No. 13/573,849 (filed Oct. 9, 2012 and entitled “RoboticSurgical Devices, Systems, and Related Methods”), and U.S. Ser. No.13/738,706 (filed Jan. 10, 2013 and entitled “Methods, Systems, andDevices for Surgical Access and Insertion”), and U.S. Pat. No. 7,492,116(filed on Oct. 31, 2007 and entitled “Robot for Surgical Applications”),U.S. Pat. No. 7,772,796 (filed on Apr. 3, 2007 and entitled “Robot forSurgical Applications”), and U.S. Pat. No. 8,179,073 (issued May 15,2011, and entitled “Robotic Devices with Agent Delivery Components andRelated Methods”), all of which are hereby incorporated herein byreference in their entireties.

Certain device and system implementations disclosed in the applicationslisted above can be positioned within a body cavity of a patient incombination with a support component similar to those disclosed herein.An “in vivo device” as used herein means any device that can bepositioned, operated, or controlled at least in part by a user whilebeing positioned within a body cavity of a patient, including any devicethat is coupled to a support component such as a rod or other suchcomponent that is disposed through an opening or orifice of the bodycavity, also including any device positioned substantially against oradjacent to a wall of a body cavity of a patient, further including anysuch device that is internally actuated (having no external source ofmotive force), and additionally including any device that may be usedlaparoscopically or endoscopically during a surgical procedure. As usedherein, the terms “robot,” and “robotic device” shall refer to anydevice that can perform a task either automatically or in response to acommand.

Certain embodiments provide for insertion of the present invention intothe cavity while maintaining sufficient insufflation of the cavity.Further embodiments minimize the physical contact of the surgeon orsurgical users with the present invention during the insertion process.Other implementations enhance the safety of the insertion process forthe patient and the present invention. For example, some embodimentsprovide visualization of the present invention as it is being insertedinto the patient's cavity to ensure that no damaging contact occursbetween the system/device and the patient. In addition, certainembodiments allow for minimization of the incision size/length. Furtherimplementations reduce the complexity of the access/insertion procedureand/or the steps required for the procedure. Other embodiments relate todevices that have minimal profiles, minimal size, or are generallyminimal in function and appearance to enhance ease of handling and use.

Certain implementations disclosed herein relate to “combination” or“modular” medical devices that can be assembled in a variety ofconfigurations. For purposes of this application, both “combinationdevice” and “modular device” shall mean any medical device havingmodular or interchangeable components that can be arranged in a varietyof different configurations. The modular components and combinationdevices disclosed herein also include segmented triangular orquadrangular-shaped combination devices. These devices, which are madeup of modular components (also referred to herein as “segments”) thatare connected to create the triangular or quadrangular configuration,can provide leverage and/or stability during use while also providingfor substantial payload space within the device that can be used forlarger components or more operational components. As with the variouscombination devices disclosed and discussed above, according to oneembodiment these triangular or quadrangular devices can be positionedinside the body cavity of a patient in the same fashion as those devicesdiscussed and disclosed above.

As best shown in FIG. 1, in certain exemplary embodiments, the device 10has two coupleable bodies 12A, 12B, each of which is rotatably coupledto one of two arms 14A, 14B as shown. The coupleable bodies 12A, 12B arealso referred to as “shoulders,” “shoulder assemblies,” “connectors,”and “connector assemblies.” More specifically, each arm 14A, 14B has acoupling link 8A, 8B that couples the arm 14A, 14B to one of thecoupleable bodies 12A, 12B. Each arm has an inner link (also referred toherein as an “inner arm,” “inner arm assembly,” “upper arm,” “upper armassembly,” “first link,” or “first link assembly”) 16A, 16B and an outerlink (also referred to herein as an “outer arm,” “outer arm assembly,”“forearm,” “forearm assembly,” “second link,” or “second link assembly”)18A, 18B. The upper arms 16A, 16B are rotatably coupled to the couplinglinks 8A, 8B, which are rotatably coupled to the coupleable bodies 12A,12B. In the right arm 14A, the upper arm 16A is rotatably coupled to theforearm 18A, while in the left arm 14B, the upper arm 16B is rotatablycoupled to the forearm 18B.

Each of the arms 14A, 14B has five degrees of freedom. That is, each arm14A, 14B has four rotatable joints or components and a single bipolartool. For example, as best shown in FIGS. 1, 5A, and 5B, the couplinglink 8A, 8B of each arm 14A, 14B has a rotatable joint 20A, 20B that isrotatable around an axis A that is perpendicular to the length of eachof the coupleable bodies 12A, 12B, as shown by arrow A1. The rotatablejoints 20A, 20B couple each of the coupleable bodies 12A, 12B to one ofthe coupling links 8A, 8B. This rotation around axis A is also called“shoulder pitch.” FIGS. 5A and 5B depict the right coupleable body 12A.More specifically, FIG. 5A is a sideview of the right body 12A, whileFIG. 5B is a cross-sectional cutaway view depicting the internal portionof the body 12A marked by line AA-AA in FIG. 5A. Further, FIG. 5Bdepicts axis A around which rotatable joint 20A rotates.

As best shown in FIGS. 1, 7A, and 7B, the coupling link 8A, 8B of eacharm 14A, 14B also has a rotatable joint 22A, 22B that is rotatablearound an axis B that is perpendicular to the axis A, as shown by arrowB1. FIGS. 7A and 7B depict the right upper arm 16A. More specifically,FIG. 7A is a top view of the right upper arm 16A, while FIG. 7B is across-section cutaway sideview depicted the internal portion of theupper arm 16A marked by line BB-BB in FIG. 7A. FIG. 7B also depicts axisB around which rotatable joint 22A rotates. The rotatable joints 22A,22B couple the coupling links 8A, 8B to the upper arms 16A, 16B. Thisrotation around axis B is also called “shoulder yaw.”

Also best depicted in FIGS. 1, 7A, and 7B, the arms 14A, 14B each have arotatable joint 24A, 24B that is rotatable around an axis C that isparallel to axis B, as shown by arrow C1. FIG. 7B depicts axis C aroundwhich rotatable joint 24A rotates. The rotatable joints 24A, 24B couplethe upper arms 16A, 16B to the forearms 18A, 18B. This rotation aroundaxis C is also called “forearm yaw.”

Additionally, as best shown in FIGS. 1 and 8B, each of the forearms 18A,18B (or a portion thereof) are configured to rotate around an axis Dthat is perpendicular to axis C, as shown by arrow D1. This rotationallows for the rotation or “roll” of the end effectors 26A, 26B coupledto the distal end of each of the forearms 18A, 18B. This rotation aroundaxis D is also called “end effector roll.”

Further, as best shown in FIGS. 1 and 8A, each of the end effectors 26A,26B, or, more specifically, certain components thereof, are configuredto rotate or move around an axis E that is perpendicular to axis D, asshown by arrow E1. This rotation or movement allows for the opening andclosing of the end effector 26A, 26B (also referred to as moving the endeffector 26A, 26B between an open and closed position), such as agrasper or gripper or scissors. This rotation around axis E is alsocalled “end effector opening/closing.” FIG. 8A is a top view of theright forearm 18A, while FIG. 8B is a cross-section cutaway sideviewdepicted the internal portion of the forearm 18A marked by line CC-CC inFIG. 8A. FIG. 8A depicts axis E around which the end effectoropening/closing occurs, while FIG. 8B depicts axis D around which theend effector roll occurs.

As best shown in FIGS. 1, 2A, 3A, 3B, 4A, and 4B, the two coupleablebodies 12A, 12B are configured to be coupled together. That is, each ofthe two bodies 12A, 12B have configurations that are mateable to eachother such that the right body 12A can mate with and couple to the leftbody 12B such that the two bodies 12A, 12B form a single body 12. In oneexample, each of the bodies 12A, 12B have a matching coupling featurethat allows the two bodies 12A, 12B to couple together such that theyare retained in that coupled configuration. As shown in FIGS. 3A, 3B,4A, and 4B, the right body 12A has a tapered notch 60 defined in onewall of the body 12A. The notch 60 is wider at the top of the notch 60than it is at the bottom. Similarly, the left body 12B has a taperedprojection 62 that is sized and configured to fit in the notch 60. Theprojection 62 is wider at the top of the projection 62 than it is at thebottom. In one embodiment, the two bodies 12A, 12B are coupled bypositioning the left body 12B such that the bottom portion of theprojection 62 can be slid into the top portion of the notch 60 and urgeddownward such that the projection 62 is positioned in the notch 60. Whenthe projection 62 is correctly positioned in the notch 60, the twobodies 12A, 12B are mated correctly and the coupling is maintained bythe mating of the notch 60 and projection 62. Alternatively, any otherknown mating or coupling feature or mechanism can be used. Thiscoupleability of the two bodies 12A, 12B allows for the two bodies 12A,12B to be coupled to each other prior to positioning the device 10 intothe body or after the two arms 14A, 14B have been inserted into thetarget body cavity.

The upper arms 16A, 16B and the forearms 18A, 18B are operably coupledto an external controller (not shown) via electrical cables thattransport both power and data. In certain embodiments, all six of thesegments are operably coupled to such connection components (alsoreferred to herein generally as “connection lines” or “connectioncomponents”), including both shoulders. In accordance with oneimplementation, two such connection components are provided, one foreach arm. As best shown in FIG. 2B, in this embodiment the cables arebus power and communication lines 30A, 30B that are disposed in orcoupled to the connector 12. The lines 30A, 30B transport power from anexternal power source (not shown) to the motors (not shown) disposed inthe arm segments 16A, 16B, 18A, 18B and further transport data to andfrom the segments 16A, 16B, 18A, 18B to the controller. According to oneembodiment, the proximal end of the lines 30A, 30B are operably coupledto an external source (not shown). According to one embodiment, theexternal source is an external controller that is a power supply and acommunication port. Alternatively, the power supply and the controllercan be separate external components. At their distal ends, the power andcommunication lines 30A, 30B are operably coupled to themicrocontrollers and the motors in the arms 14A, 14B as well as themicrocontrollers and motors in the shoulders. More specifically, asshown in FIGS. 1 and 2B, the right line 30A extends from the rightconnector 12A to the right upper arm 16A and is positioned through ahole 52A formed in a top portion of the upper arm 16A. In the upper arm16A, the line 30A is operably coupled to the at least onemicrocontroller and the at least one motor (not shown) in the arm 16A.From the upper arm 16A, the line 30A extends out of a hole 54A and tothe forearm 18A, where the line 30A is coupled to the at least onemicrocontroller and the at least one motor (not shown) in the forearm18A.

Similarly, as also shown in FIGS. 1 and 2B, the left line 30B extendsfrom the left connector 12B to the left upper arm 16B and is positionedthrough a hole 52B formed in a top portion of the upper arm 16B. In theupper arm 16B, the line 30B is operably coupled to the at least onemicrocontroller and the at least one motor (not shown) in the arm 16B.From the upper arm 16B, the line 30B extends out of a hole 54B and tothe forearm 18B, where the line 30B is coupled to the at least onemicrocontroller and the at least one motor (not shown) in the forearm18B. In certain embodiments, the lines 30A, 30B are reinforced ormechanically strain-relieved at the access points to the arm segments(such as holes 52A, 52B, 54A, 54B) to minimize or eliminate damage tothe lines 30A, 30B caused by strain as a result of the movement of thearms 14A, 14B. Additionally the lines 30A, 30B are sealed at the accesspoints to prevent fluid ingress into the robot.

As best shown in FIGS. 1, 2A, and 2B, two cautery lines 32A, 32B arealso disposed in or coupled to the connector 12A, 12B. In this depictedembodiment, the right cautery line 32A is attached to an exteriorportion of the right connector 12A (as best shown in FIG. 1), while theleft cautery line 32B is attached to an exterior portion of the leftconnector 12B (as best shown in FIGS. 2A and 2B). The proximal ends ofthe lines 32A, 32B are coupled to an external power source (not shown).As best shown in FIG. 2B, the right cautery line 32A extends from theright connector 12A to the right forearm 18A, in which the line 32A isoperably coupled to the end effector 26A. In one implementation, theportion of the line 32A that extends from the connector 12A to theforearm 18A is coupled to an exterior portion of the upper arm 16A asshown. Alternatively, the line 32A could extend through an interiorportion of the upper arm 16A. Similarly, the left cautery line 32Bextends from the left connector 12B to the left forearm 18B, in whichthe line 32B is operably coupled to the end effector 26B. In oneimplementation, the portion of the line 32B that extends from theconnector 12B to the forearm 18B is coupled to an exterior portion ofthe upper arm 16B as shown. Alternatively, the line 32B could extendthrough an interior portion of the upper arm 16B.

As best shown in FIGS. 1 and 2B, a dual suction/irrigation line 34A, 34Bis also coupled to the connector 12. The dual line 34A, 34B is a knownline that is comprised of at least one line that can be alternativelyused for suction or irrigation. In certain other embodiments, more thanone line can be provided provided, thus providing for suction andirrigation. In the embodiment depicted in FIGS. 1 and 2B, at itsproximal end, the dual suction/irrigation line 34 is coupled to anexternal irrigation/suction component (not shown) that provides suctionor irrigation to the lumen. In one embodiment, the line 34A, 34B iscoupled at its proximal end to a valve having two separate lines: oneline extending to a known suction device and the other line extending toa known irrigation device. This commercially-available valve is knowngenerally as a “trumpet valve.” Alternatively, the dual line 34A, 34B iscoupled to any known external component that provides suction andirrigation, or is coupled to two separate devices, one providing suctionand the other providing irrigation. Alternatively, it is understood thattwo separate lines can be provided—a suction line and an irrigationline. In this embodiment, the dual suction/irrigation line 34A iscoupled to an exterior portion of the right connector 12A. Thesuction/irrigation line 34A extends from the right connector 12A to theright arm 14A, where the line 34A is coupled to an exterior portion ofthe upper arm 16A and to an exterior portion of the forearm 18A asshown.

In one embodiment, the forearm 18A has an attachment component 36configured to couple the suction/irrigation line 34 to the forearm 18A.In this particular exemplary embodiment, the attachment component 36 isan attachment collar 36 configured to be positioned around the forearm18A and coupled to the line 34 such that the collar 36 helps to keep theline 34 coupled to the forearm 18A. At its distal end, the dualsuction/irrigation line 34 is operably coupled to the cautery scissors26A.

As shown in FIGS. 2A and 2B, the connector 12 has a laparoscope lumen 38defined in the connector 12. The lumen 38 is configured to receive anystandard laparoscopic imaging device. Further, each of the twocoupleable connectors 12A, 12B defines an insertion rod lumen 40A, 40B.Each lumen 40A, 40B is configured to receive an insertion rod 42A, 42B.

In accordance with one implementation, each of the power andcommunications lines 30A, 30B, the cautery lines 32A, 32B, and the dualsuction/irrigation line 34 are all coupled with or disposed in theconnector 12 such that a seal is maintained between the connector 12 andthe access port (not shown) mounted to the patient. That is, as bestshown in FIG. 6, the connector 12 (and the two connector bodies 12A,12B), according to one embodiment, has grooves or channels 70 definedalong the outer surface of the two bodies 12A, 12B such that the variouslines and cables (including the power and communications lines 30A, 30B,the cautery lines 32A, 32B, the suction/irrigation line 34, and anyother lines or cables that might be incorporated into the device) arepositioned in those grooves or channels 70. The positioning of the linesor cables in the grooves or channels 70 helps to maintain a smooth outerperimeter around the outer surface of the connector 12, thereby ensuringa successful fluidic seal with the access port when the connector 12 ispositioned therethrough. It is understood that the access port can beany known port for use with laparoscopic surgical tools, including theport devices described in U.S. patent application Ser. No. 13/738,706,filed on Jan. 10, 2013, which is hereby incorporated herein by referencein its entirety. In certain exemplary embodiments, the access port canbe readily removed, cleaned and sterilized.

According to one implementation, the arms 14A, 14B are configured toreceive a fluid sealing component over the arms 14A, 14B. That is, asbest shown in FIG. 1, each of the coupleable connectors 12A, 12B, has achannel 44A, 44B defined around the connectors 12A, 12B and each of thearms 14A, 14B has a channel 46A, 46B defined around a distal portion ofthe forearms 18A, 18B. Fluid sealing protective sleeves (not shown),such as those, for example, described in U.S. application Ser. No.13/573,849, filed on Oct. 9, 2012, which is hereby incorporated byreference herein in its entirety, are positioned over each arm 14A, 14Band the ends of each sleeve are positioned in one of the channels 44A,44B, 46A, 46B such that the sleeves are coupled to the arms 14A, 14Bsuch that the sleeves create a fluidic seal around each arm 14A, 14B,whereby moisture and liquid are prevented from ingressing into the arms14A, 14B.

Each of the joints described above is operably coupled to a motor via ageartrain (not shown). Further, each joint is also operably coupled to amicrocontroller. In addition, each joint is operably coupled to at leastone position sensor. According to one embodiment, each joint is coupledto both a relative position sensor and an absolute position sensor.According to another embodiment, each joint has at least a relativeposition sensor.

As best shown in FIGS. 2C and 2D, the configuration of the connector 12and the arms 14A, 14B in this embodiment provide a minimalcross-sectional area for the device 10, thereby allowing for easyinsertion of the device 10 through a small incision and into a smallcavity of a patient. That is, the coupling of the arms 14A, 14B to theconnector 12 via the coupling links 8A, 8B, along with the ability toposition the arms 14A, 14B as shown in FIGS. 2C and 2D, results in anarrower device 10 that can fit through smaller incisions in comparisonto devices that are wider/have larger cross-sections. In use, the arms14A, 14B of the device 10 can be positioned as shown in these figuresprior to insertion into a patient's cavity. The device 10 can then bepositioned through an incision in a single linear motion. In oneembodiment, the device 10 is inserted one arm at a time. That is, thetwo coupleable bodies 12A, 12B with arms attached are positioned in thepatient's cavity prior to coupling the two bodies 12A, 12B together.Alternatively, the device 10 is inserted as a single unit, with the twobodies 12A, 12B already coupled together.

FIGS. 5C and 5D depict a close-up of the right connector 12A, accordingto one embodiment. It is understood that the internal components of theright connector 12A as described herein are substantially similar to theequivalent components in the left connector 12B, so the followingdescription shall encompass those equivalent components as well. As bestshown in FIG. 5D, the right connector 12A has a connector motor 160 thatis operably coupled to a bevel motor gear 162. The bevel motor gear 162is operably coupled to a bevel driven gear 164, which constitutes joint20A discussed above. The drive gear 164 is supported in this embodimentby two bearings 166 and is operably coupled to the right coupling link8A, which is also described above. In one implementation, a magneticabsolute position encoder 168 (also shown in FIG. 5C) and an encodermagnet 170 are operably coupled to the driven gear 164, and are therebyconfigured to provide information about the position of the gear 164. Asbest shown in FIG. 5C, a motor control board 172 is positioned in thehousing of the connector 12A.

In accordance with one embodiment, the right and left upper arms 16A,16B, including the coupling links 8A, 8B, have configurations that areidentical or substantially similar and are simply mirror versions ofeach other. Alternatively, they can have some different components asnecessary for the specific end effectors that might be coupled to theforearms 18A, 18B.

FIGS. 7A, 7B, and 7C depict a right upper arm 16A, according to oneembodiment. It is understood that the internal components of the rightupper arm 16A as described herein are substantially similar to theequivalent components in the left upper arm 16B, so the followingdescription shall encompass those equivalent components as well. Theupper arm 16A has two motors 200, 202. The first motor 200 is configuredto actuate the shoulder shaft 204 to rotate in relation to the couplinglink 8A, thereby rotating around axis B. The second motor 202 isconfigured to actuate the elbow shaft 206 to rotate in relation to theforearm 18A, thereby rotating around axis C.

As best shown in FIG. 7B, the first motor 200 is operably coupled tomotor gear 208, which is operably coupled to the driven gear 210. Thedriven gear 210 is operably coupled to the shoulder shaft 204 such thatrotation of the driven gear 210 causes rotation of the shoulder shaft204. The shaft 204 is supported by bearings 216A, 216B. The motor 202 isoperably coupled to motor gear 212, which is operably coupled to thedriven gear 214. The driven gear 214 is operably coupled to the elbowshaft 206 such that rotation of the driven gear 214 causes rotation ofthe elbow shaft 206. The shaft 206 is supported by bearings 218A, 218B.

Each of the shafts 204, 206 is operably coupled to an encoder magnet222A, 222B, each of which is operably coupled to an absolute positionmagnetic encoder 220A, 220B. The encoders 220A, 220B work in a fashionsimilar to the position encoders described above. At least one motorcontrol board 224 is positioned in the housing of the upper arm 16A asbest shown in FIG. 7C.

In contrast, in this implementation as shown in FIGS. 1 and 2A, theright and left forearms 18A, 18B are not identical. That is, the rightforearm 18A has an end effector 26A further comprising cautery scissors26A. According to one embodiment, the cautery scissors 26A is a“quick-change” mono-polar cautery scissors 26A. That is, the cauteryscissors 26A can be coupled to or removed from the forearm 18A withoutthe need to assemble or disassemble any other components. Morespecifically, in this exemplary embodiment, a commercially-availablecautery scissors 26A called the ReNew Laparoscopic Endocut ScissorsTip™, which is available from Microline Surgical, Inc., located inBeverly, Mass., is removeably coupled to the forearm 18A. Alternatively,any known easily removeable end effector or any known mechanism ormethod for providing easy coupling and uncoupling of the end effector26A can be used. In a further alternative, the end effector 26A can beany known end effector for use with an arm of a robotic surgical device.

One exemplary embodiment is depicted in FIGS. 8A-8D. FIGS. 8A-8D depictseveral views of the right forearm 18A according to one implementation.FIG. 8C is a cross-sectional cutaway view of the forearm 18A that isperpendicular to the plane of the line CC-CC of FIG. 8A, while FIG. 8Dis a cross-sectional cutaway view of the forearm along line CC-CC ofFIG. 8A. The forearm 18A has two motors 80, 82. As best shown in FIG.8C, the motor 80 is operably coupled to the end effector 26A such thatthe motor 80 actuates the end effector 26A to move between its open andclosed positions. As best shown in FIG. 8D, the motor 82 is operablycoupled to the end effector 26A such that the motor 82 actuates the endeffector 26A to “roll,” which is rotation around an axis parallel to thelongitudinal length of the arm 18A.

Focusing on FIG. 8C, the motor 80 actuates the end effector 26A to openand close in the following fashion. The motor 80 has a motor gear 84that is operably coupled to a driven gear 86. The driven gear 86 isoperably coupled to a connector component 88 such that the connectorcomponent 88 rotates when the driven gear 86 rotates. Connectorcomponent 88 is supported by two bearings (not shown). The connectorcomponent 88 has a threaded inner lumen 88A and is operably coupled to atranslation component 90. More specifically, the translation component90 has a proximal threaded projection 90A that is threadably coupled tothe threaded inner lumen 88A such that rotation of the connectorcomponent 88 causes axial movement of the translation component 90. Inaddition, as best shown in FIG. 8D, the translation component 90 has aprojection 90B extending from an outer circumference of the component 90such that the projection 90B is positioned in a slot 92 that constrainsthe translation component 90 from rotating. As such, when the drivengear 86 rotates and thus causes the connector component 88 to rotate,the rotation of the connector component 88 causes the translationcomponent 90 to move axially along the longitudinal axis of the arm 18A.

The translation component 90 defines a lumen 90C at its distal end thatis configured to receive the coupling component 94, as best shown inFIG. 8C. Further, the lumen 90C contains at least one bearing 96 that ispositioned between the translation component 90 and the couplingcomponent 94 such that the translation component 90 and the couplingcomponent 94 are rotationally independent of each other. That is, thecoupling component 94 can rotate inside the lumen 90C of the translationcomponent 90 while the translation component 90 does not rotate. Thecoupling component 94 has a threaded lumen 94A configured to receive arod (or pin) 98 that has external threads on its proximal end that arethreadably coupled to the threaded lumen 94A of the coupling component94. The distal end of the rod 98 is slidably positioned in the endeffector housing 100 such that the rod 98 can slide axially back andforth in relation to the housing 100. The rod 98 is operably coupled tothe first and second blades 102A, 102B of the scissors 26A via linkages(not shown) such that the axial movement of the rod 98 causes the blades102A, 102B to pivot around the pivot axis 104, thereby causing theblades 102A, 102B to open and close. More specifically, in oneembodiment, movement of the rod 98 in a distal direction (toward thescissors 26A) causes the blades 102A, 102B to move away from each othersuch that the scissors 26A move toward an open position, while proximalmovement of the rod 98 causes the scissors 26A to move toward a closesposition.

Focusing on FIG. 8D, the motor 82 actuates the end effector 26A to rollin the following fashion. The motor 82 has a motor gear 104 that isoperably coupled to a driven gear 106. The driven gear 106 is operablycoupled to a roll shaft 108 such that the roll shaft 108 rotates whenthe driven gear 106 rotates. The at least one bearing 112 disposedaround the roll shaft 108 allows the roll shaft 108 to rotate inrelation to the forearm 18A. The roll shaft 108 is operably coupled torotational connector 110, such that roll shaft is constrained linearlyand rotationally. Housing 100 is threadably coupled to rotationalconnector 110, such that the two components are operably coupled, againconstrained linearly and rotationally. In certain embodiments, rollshaft 108 does not have any threads. As such, the roll shaft 108, thehousing 100, and the rotational connector 110 are all coupled togethersuch that they are capable of rotating together. Thus, actuation of themotor 82 results in rotation of the housing 100 and thus rotation of theend effector 26A. According to one embodiment, the forearm 18A also hasat least one position sensor to provide information to an externalcontroller (not shown) or a microcontroller regarding the position ofthe end effector 26A.

The electrical connection required for the cautery feature of the endeffector 26A is maintained in the following fashion. An electricalcontact pin 114 is slidably positioned within the lumen 88A of theconnector component 88 and is electrically coupled at its proximal endto the cautery line 32A discussed elsewhere herein (and depicted inFIGS. 1 and 2B). The lumen 88A contains bifurcated leaf springs whichmaintain electrical contact and provide long life to mechanism. This wasaccomplished by taking an off the shelf socket connector and pressfitting the socket portion into part 88. At its distal end, the pin 114is electrically coupled to the translation component 90, which iselectrically coupled through the other coupling components discussedabove to the blades 102A, 102B of the end effector 26A, thereby allowingfor electrical coupling of the cautery line 32A to the end effector 26A.

The left forearm 18B has an end effector 26B that is a cautery grasper26B, as shown in FIGS. 9A and 9B. According to one embodiment, thecautery grasper 26B is an integrated bi-polar cautery grasper 26B. Inthis context, “integrated” is intended to mean that the grasper 26B isan integral part of the forearm 18B such that replacement of the grasper26B with another end effector would require disassembly of the forearm18B. Alternatively, the grasper 26B is not an integral part of theforearm 18B but rather is easily removable and interchangeable withother end effectors. For example, in one embodiment, the end effector26B is a “quick change” end effector 26B similar to the right endeffector 26A as described above.

FIGS. 9A and 9B depict the left forearm 18B according to oneimplementation. FIG. 9A is a cross-sectional cutaway view of the forearm18B along line DD-DD of FIG. 2D, while FIG. 9B is a cross-sectionalcutaway view of the forearm along a line that is perpendicular to theplane of line DD-DD of FIG. 2D. The forearm 18B has two motors 120, 122.As best shown in FIG. 9A, the motor 120 is operably coupled to the endeffector 26B such that the motor 120 actuates the end effector 26B to“roll,” which is rotation around an axis parallel to the longitudinallength of the arm 18B. As best shown in FIG. 9B, the motor 122 isoperably coupled to the end effector 26B such that the motor 122actuates the end effector 26B to move between its open and closedpositions.

Focusing on FIG. 9A, the motor 120 actuates the end effector 26B to rollin the following fashion. The motor 120 has a motor gear 124 that isoperably coupled to a driven gear 126. The driven gear 126 is operablycoupled to a end effector housing 128 such that the housing 128 rotateswhen the driven gear 126 rotates. As such, actuation of the motor 120causes rotation of the end effector 26B. The at least one bearing 130positioned around a proximal portion of the driven gear 126 to allow thegear 126 and the housing 128 to rotate in relation to the arm 18B. AnO-Ring 132 forms a seal around the housing 128, but does not support theshaft and does not aid in its rotation or constraint. Applying a radialloaded to the O-ring 132 could potentially compromise the seal which isits primary and sole function.

Focusing on FIG. 9B, the motor 122 actuates the end effector 26B to openand close in the following fashion. The motor 122 has a motor gear 134that is operably coupled to a driven gear 136. The driven gear 136 isoperably coupled to a connector component 138, which is threadablycoupled to an inner lumen 136A of the driven gear 136 such that theconnector component 138 translates when the driven gear 136 rotates. Theconnector component 138 is operably coupled to connector rods 140A,140B, which are operably coupled at their proximal ends to a slip ring142 (as best shown in FIG. 9A). The connector component 138, rods 140A,140B, and slip ring 142 are coupled to each other rotationally andaxially such that rotation of the connector component 138 causesrotation of both the rods 140A, 140B and the slip ring 142. Further, asthe driven gear 136—rotates, the assembly of the coupled components 138,140A, 140B, 142 moves axially in relation to the driven gear 136. Theassembly 138, 140A, 140B, 142 is also coupled to the end effectorhousing 128 such that housing 128 rotates when the assembly 138, 140A,140B, 142 rotates. However, the assembly 138, 140A, 140B, 142 can moveaxially independently of the housing 128. Each of the rods 140A, 140B isoperably coupled to one of the fingers 148A, 148B of the grasper 26B viaa linkage (not shown) within the housing 128. As the rods 140A, 140Bmove axially, they move the linkages, thereby causing the fingers 148A,148B to move between their open and closed positions. The driven gear136 thus causes translation, not rotation of the assembly 138, 140, 142.Its rotation is contrained by the housing 128, which in turn isconstrained by the driven gear 126, which in turn is rotationallyconstrained by motor gear 124, which is in turn constrained by motor120. Therefore, it is the motor 120 that provides the rotationalconstraint in a similar fashion to the projection 90B in FIG. 8D. Incontrast to the right arm, the linear motion and the rotational motionof this mechanism is coupled. When a user wishes to roll the tool andmaintain a constant open or closed position, both motors 120, 122 mustbe actuated and match speed. When a user wishes to open or close thetool, the motor 122 must be actuated and hold position to constrain therotation.

According to one embodiment, the forearm 18B also has a set of positionsensors to provide information to an external controller (not shown) ora microcontroller regarding the position of the end effector 26B. In theimplementation as shown in FIG. 9A, an array of LEDs 144 and a set ofposition sensors 146 are positioned in the forearm 18B such that theaxial position of the end effector 26B can be determined based on theposition of the slip ring 142. More specifically, the array of LEDs 144are positioned on one side of the ring 142 and the sensors 146 arepositioned on the other side such that the position of the slip ring 142can be determined based on which sensors 146 are sensing light emittedfrom LEDs 144 (and which sensors 146 are not). This information aboutthe position of the slip ring 142 can be used to determine the positionof the end effector 26B.

As best shown in FIG. 10, in certain exemplary embodiments of thepresent invention 300, the onboard microcontrollers, or PCBs 302, areoperably connected with uniform flex tapes 304. In certain embodiments,the various PCBs are identical and the flex tapes are universallyadaptable.

In certain exemplary embodiments of the forearm, 18 as shown in FIGS.11A-11F and 12, the surgical device further comprises a linear slip ringassembly 402 (best shown in FIGS. 11A-11F) for use with an end effector,such as a bipolar cautery end effector, or “tool assembly” 460 which isshown generally in FIG. 12. In these embodiments, the bi-polar cauteryend effector having two grasper fingers operates by coupling the twograsper fingers to separate electrical channels. The linear slip ringassembly 402 has an opening 402A that receives the tool assembly 460(depicted in FIGS. 11F and 12) so as to provide electrical andmechanical communication between the tool assembly and the linear slipring, and thereby couple the two grasper fingers to a power source. Incertain embodiments, this is an external power source.

In certain implementations, the linear slip ring assembly 402 is a noveltwo-channel linear slip ring assembly 402 capable of allowing bothrotating motion and translating motion of the tool assembly 460 disposedtherein. The linear slip ring assembly also contains two electricalchannels (as described below) that are isolated from one anotherthroughout the assembly and connect to the linear slip ring 402 so as topass bi-polar cautery power to the grasper fingers as they roll and openor close.

In exemplary embodiments, the linear slip ring assembly 402 has a firststator pair 408 and second stator pair 410. The first and second statorpairs 408, 410 are each spring loaded onto the housing 412 by U-springs414, 416 and are operably coupled with the corresponding slip ringrotors 452, 454 of the tool assembly 460 (shown in FIG. 12). The slipring rotors 452, 454 are capable of both translational and continuousrotation of the end effector. An insulator 418 separates the slip ringrotors 452, 454 to maintain electrical isolation.

Focusing on FIG. 12, in operation, exemplary end effector embodiments440 having the linear slip ring assembly 440A further comprise a toolassembly 460 having a roll gear 442, which is permanently bonded to thetool housing 444. In operation, by rotating the roll gear 442, the toolhousing assembly, 460 as described previously, all of the tool rotates.This rotation includes the grasper 448, the roll gear 442, the leadscrew450, and the slip ring rotators 452, 454. In these embodiments, the rollgear 442 is fixed in place axially in the forearm assembly 440 andoperably coupled to the roll motor 456. In these implementations, theroll gear 442 is not free to move linearly, and can only moverotationally. Actuating the roll motor 456 thus causes the entire toolassembly 460 to rotate.

In exemplary embodiments, a linear motor 462 is coupled to an internallythreaded driven gear (shown in reference to FIG. 9B as the driven gear136). This driven gear 136 is in turn threadably coupled to theconnector component, or “leadscrew” 450 (shown in FIG. 9B as theconnector component 138). The driven leadscrew drives the leadscrew 450linearly so as to open and close the grasper 448.

Further, the leadscrew 450 and roll gear 442 are coupled together. Inoperation, in order to achieve pure roll, both the roll gear 442 and thedriven leadscrew must rotate at the same speed. This is done so thatthere is no relative angular velocity between the leadscrew 450 and theleadscrew gear. By way of example, if the roll gear 442 were to spin(and the tool 460 spin with it), while the driven leadscrew gearmaintained position, the leadscrew 450 would be spinning within theleadscrew gear and causing translation, in the depicted embodiment theopening or closing of the grasper 448.

Similarly, in order to achieve pure opening or closing of the grasper448, the roll gear 442 must hold position while the driven leadscrewgear rotates and drives the leadscrew 450 linearly. If the roll gear 442were free to spin while the driven leadscrew gear operates, no relativemotion between the leadscrew 450 and leadscrew gear would occur and thusthere would be no linear translation, and thus no opening or closing ofthe grasper 448.

In these exemplary embodiments, the cautery slip ring rotors 452, 454are permanently coupled mechanically to the leadscrew 450 along an axis,but remain isolated 418 electrically from the leadscrew 450, such thatthe cautery slip ring rotors 452, 454 translate with the leadscrew 450and rotated when entire tool 460 rotates.

Thus, in certain exemplary embodiments, the entire tool 460 isrotationally coupled. The proximal portion 470 (including the leadscrew450 and the cautery slip ring rotors 452, 454) can translate withrespect to the distal portion 480 (including the roll gear gear 442, thetool housing 440 and the grasper 448). This translation drives thegrasper 448 open and closed. Further, and as discussed in relation toFIG. 11A-F, each of the cautery slip ring rotors 452, 454 iselectrically coupled to one grasper jaw 448A, 448B. As previouslydiscussed in reference to FIG. 11A-11F, each of the cautery slip ringrotors 452, 454 are also electrically coupled to a stator pair 408, 410,and is electrically isolated from every other element in the system.

According to another implementation, the surgical device forearm 18further comprises a linear encoder, as is depicted in FIGS. 11A-F anddiscussed further herein in reference to 13A-D. Linear encoders serve asabsolute position sensors by assessing the absolute position of the endeffector or forearm. In these embodiments, the forearm 18 furthercomprises a pixel array 420 and LED array 422, as best shown in FIGS.11A & 11B, which function together to determine the position of aspectsof the surgical device. By way of example, in these embodiments, thisfunctions is performed by broadcasting and receiving a signal—such asLED light—to determine the position of those aspects by assessingshadows or breaks in the LED light. Data from the magnetic absoluteposition encoder (discussed in relation to FIGS. 5C and 7B herein) andthe linear position encoder can both be used as feedback sensors in thecontrol algorithm. In certain implementations, the absolute linearposition optical encoder is coupled to the gripper translation assemblyand the custom relative rotary position optical encoder is coupled tothe motor shaft, and both are used as the feedback sensors in thecontrol algorithm. This is discussed further herein in relation to FIG.13A-13D.

In the implementation shown in FIG. 11A-11F, an array of LEDs 422 andthe pixel array 420 are positioned on the housing 412 such that theaxial position of the end effector (not shown) can be determined basedon the position of the projection from the LED array 422. Morespecifically, the array of LEDs on one side of the housing and the pixelarray 420 are positioned on opposite sides of the housing 412 such thatthe position of the LED projection can be determined based on whichsensors are sensing light emitted from LEDs (and which sensors are not)based on the position of the end effector disposed within that channel.

In certain embodiments, the motor control boards are integrated into theforearm housing, best shown as reference numbers 80 in FIG. 8C and 122in FIG. 9B. The linear position encoder is attached to the back of thetool drive motor. In certain embodiments, the surgical device comprisesa rotary relative position encoder having a fan with a plurality ofequally spaced blades operationally coupled to the dependant motor. Asthe dependant motor spins, these blades break a beam between an infraredsensor and receiver, thereby counting rotations of the motor.

Again, according to certain additional implementations, the surgicaldevice has a linear encoder 500, as depicted in FIG. 13A-D. In theseimplementations, the LED emitter 522 is a PCB further comprising anarray of LEDs. In these implementations, the receiver array 520 is alsoa PCB, and further comprises a linear array of light sensitive pixels.In certain implementations, the receiver array 520 comprises a COTSintegrated circuit. In such exemplary embodiments, each element ofoutput of the linear array 522 is continuously sampled by the receiverarray 520 and the voltage level is recorded. By way of example, in theseimplementations, the voltage level is directly proportional to theamount of light collected by the pixel during the last sample period,such that increases in receive light correlates to increases in voltage,so as to communicate feedback concerning the absolute position of thesurgical device and end effector.

In the exemplary embodiments of the linear encoder 500 depicted in FIGS.13A-13D, the receiver array 520 and the LED emitter 522 are supported bya support piece 524 with at least one window (one labeled 526, othersnot shown), and a slit 528. According to one embodiment, the supportpiece 524 is made of machined delrin. The window 526 or windows allowlight to pass from the LED emitter 522 to the receiver 520. The supportpiece 524 can accommodate a leadscrew 530. In certain implementations,the leadscrew 530 further comprises a slotted extrusion 532 whichtranslates linearly to the slit 528. A gap in the extrusion 532 allowslight to pass from the LED emitter 522 to the receiver 520. As theleadscrew 530 translates, the slot in extrusion 532 movescorrespondingly, thereby casting a shadow on the receiver everywhereexcept in the location of the slot. In this way, absolute position ofthe leadscrew 530 is determined.

In certain implementations, a second extrusion 552 slides in a slot 550in the second support piece 540. This slot 550 has a tighter fit thanbetween the slotted extrusion 532 and slot 528. In this way the secondsupport piece 540 can act as the rotational constraint for the leadscrew530. In this implementation, the second extrusion 552 causes friction(or “rubs”) against the second support piece 540 and slot 550.Conversely, the slotted extrusion 532 does not rub in slot 528. Thisimplementation prevents material build up, deformation, or otherdeterioration of the sensor unit.

Thus, certain embodiments of the present invention provide redundantposition sensing. For example, each forearm may have a relative positionsensor. In these embodiments, each forearm also may further comprise anabsolute position encoder. As would be apparent to those of skill in theart, the coupling of the absolute and relative position sensing allowsfor both homing of the device and the addition of safety features.

While multiple embodiments are disclosed, still other embodiments willbecome apparent to those skilled in the art from the following detaileddescription, which shows and describes illustrative embodiments. As willbe realized, the various implementations herein are capable ofmodifications in various obvious aspects, all without departing from thespirit and scope thereof. Accordingly, the drawings and detaileddescription are to be regarded as illustrative in nature and notrestrictive.

Although the inventions have been described with reference to preferredembodiments, persons skilled in the art will recognize that changes maybe made in form and detail without departing from the spirit and scopethereof.

What is claimed is:
 1. A modular surgical robotic system, comprising:(a) a port traversing the body of a patient; (b) a modular roboticdevice sized to be positioned completely within a patient furthercomprising: (i) a plurality of coupleabe bodies, further comprising afirst shoulder component and a second shoulder component, the coupleablebodies capable of traversing the port from the exterior to interior ofthe patient; (ii) a first movable segmented robotic arm operationallyconnected to the first shoulder component; (iii) a second movablesegmented robotic arm operationally connected to the second shouldercomponent; (iv) a first operational component operationally connected tothe first robotic arm; and (v) a second operational componentoperationally connected to the second robotic arm; and (c) an operationssystem for control of the modular robotic device from outside thepatient by way of the port and coupleable bodies, the operations systemin electrical communication with the modular robotic device.